Additive manufacturing of extended structures

ABSTRACT

An extended structure additive manufacturing device and method are provided. The device includes a movable material bonding component and a movement mechanism which enable the device to create parts outside the conventional additive manufacturing device print volumes defined by the device and its print-head. Methods of making parts involve creating a portion of a part and moving the extended structure additive manufacturing device relative to the part and printing a second portion of the part. Parts incapable of being formed using a conventional additive manufacturing device may be made using the extended structure additive manufacturing device and/or methods disclosed herein.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/877,542, filed Sep. 13, 2013, and entitled “ExtendedStructure Additive Manufacturing Method” and claims the benefit of U.S.Provisional Patent Application No. 61/893,286, filed Oct. 21, 2013, andentitled “Additive Manufacturing Devices Configured For VariousEnvironments,” the entire contents of both being incorporated herein byreference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to manufacturing, and moreparticularly to additive manufacturing of large structures in variousenvironments.

BACKGROUND

Additive manufacturing processes sequentially bond materials together inorder to form the completed part. Creation of the part is computercontrolled and produces the part according to three-dimensionalrepresentations of the desired part or other part creation instructions.Material, also known as “feedstock,” may be bonded together via fusinglayers or other small portions of material together.

Many current additive manufacturing techniques produce parts of limitedsize. The size of the part produced is constrained by the build volumeof the additive manufacturing device. The build volume is the area inwhich the additive manufacturing device may create a part. A buildvolume is often defined in an XY plane by the area in which the additivemanufacturing device may deposit or otherwise bond feedstock in formingthe desired part. For example, in fused deposition modeling devices, theXY plane is defined by the lateral movement in the XY plane of theextruder which creates layers of the desired part. The initial layer isdeposited onto a build platform or tray and subsequent layers areattached. The build volume is limited in the Z-direction by the maximumrelative distance achievable between the build platform and the extruderor other bonding device. In some additive manufacturing devices, thebuild platform is connected to a z-axis step motor and moves as the partis created. In other devices, the extruder moves in the z-axis inaddition to the x- and y-axes.

The size of the build volume is an inherent limitation of currentadditive manufacturing devices. Because this is a given volume, acontinuous part can never grow larger than the build volume of a givenmachine. This poses a severely limiting problem where no object can beproduced larger than the machine that is creating it. Today's additivemanufacturing machines are growing print volume size in order toaccommodate larger parts, but still there is an inevitable size limit onthese machines. For instance, no additive manufacturing machine could beconceivably large enough to build an entire sky-scraper within its buildvolume; the machine would be far too large.

The size constraint placed on all additive manufacturing machines is abottleneck. It severely limits the possible objects that could be builtwithout any post machining to create the final part or structure.

Processes, such as those described in U.S. patent application Ser. No.14/020,658 to Douglas, A., et al., have been created which produce largeparts by dividing the desired part design into subparts which may beproduced via additive manufacturing devices having limited buildvolumes. Connection features are added to each subpart design, enablingsubparts to be connected together after production.

Given the foregoing, additive manufacturing devices which produce large,continuous parts without providing a build volume larger than the partitself are needed.

SUMMARY

This Summary is provided to introduce a selection of concepts. Theseconcepts are further described below in the Detailed Descriptionsection. This Summary is not intended to identify key features oressential features of this disclosure's subject matter, nor is thisSummary intended as an aid in determining the scope of the disclosedsubject matter.

Aspects of the present disclosure meet the above-identified needs byproviding apparatus, systems, and methods which enable additivemanufacturing of large continuous parts. Such parts or structures may beconstructed without providing a build volume larger that the structurebeing produced. In various aspects, additive manufacturing devices inaccordance with the present disclosure may function in environments suchas space environments, microgravity environments, terrestrialenvironments, free fall environments, other controlled environments, andthe like.

In an aspect, an extended structure additive manufacturing device isdisclosed which includes a material bonding component such as anextruder, a body housing the material bonding component and apositioning system which positions the material bonding component andthe part being created relative to one another. The positioning systemmay include two sub-systems: a part positioning system and a bondingcomponent positioning system. The bonding component system may be atraverse system which positions the material bonding component withinthe body in an XY plane, enabling the material bonding component tocreate layers of the desired part. The bonding component positioningsystem may optionally include z-axis movement components, enablingmultiple layers of the part to be created without utilization of thepart positioning system. The part positioning system is configured tomove the device relative to the part being created via rollers, claws,thrusters, or the like.

Devices in accordance with the present disclosure enable production ofparts larger than any given build volume. With the extended structureadditive manufacturing method, the device moves as it builds athree-dimensional part. As the device moves, the part being builtextends beyond the device. The device can move by interfacing with wormgears, wheels, propulsion, or other known methods of traversing.

Devices in accordance with the present disclosure have many uses,including but not limited to building structures in outer space (e.g.,large communications dishes), building extended beams or cross sectionsfor construction of buildings on Earth, and building any large objectthat can't be built within a typical additive manufacturing device'slimitations.

In some aspects, devices in accordance with the present disclosure mayproduce parts larger than the given build volume of a conventionaladditive manufacturing machine that lacks any of the movable engagementmechanisms as discussed herein that engage a portion of the part beingprinted and allow the part to extend away from the device

In various aspects, devices may include one or more arms or othermovable engagement mechanisms adapted or configured to engage with aportion of the printed material so that the material bonding componentand the printed part move relative to one another during printing and/orone or more other such propulsion mechanisms that move the body or frameof the device relative to the printed material during printing.

In another aspect, an extended structure additive manufacturing deviceincludes a movable material bonding component which prints a printedmaterial to form a part, one or more arms, rollers, tracks, worms, orother such movable engagement mechanisms or propulsion mechanism thatmay be adapted or configured to engage with a portion of the printedpart to provide relative movement between the device and the printedpart and a body or frame that is open adjacent to the print-head so thatthe printed part extends away from the device during printing.

In another aspect, an extended structure additive manufacturing deviceincludes thrusters configured to maneuver the device in space (e.g.,around a large structure). The device further includes gripping armswhich contact part as it is created, thereby enabling the device to moveor travel over larger distances via thrusters and move finer distancesvia the movement of gripping arms. Part may be created via fine movementcaused by gripping arms.

Further features and advantages of the present disclosure, as well asthe structure and operation of various aspects of the presentdisclosure, are described in detail below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present disclosure will become moreapparent from the Detailed Description set forth below when taken inconjunction with the drawings in which like reference numbers indicateidentical or functionally similar elements.

FIG. 1 is a perspective view of an extended structure additivemanufacturing device producing an extended part, according to an aspectof the present disclosure.

FIG. 2 is an exploded perspective view of an extended structure additivemanufacturing device producing an extended part, according to an aspectof the present disclosure.

FIG. 3 is a bottom perspective view of an extended structure additivemanufacturing device producing an extended part and showing the materialbonding system, according to an aspect of the present disclosure.

FIGS. 4A & B are views of an extended structure additive manufacturingdevice comprising geared wheels and producing a part having geared guidetopography, according to an aspect of the present disclosure.

FIG. 5 is an exploded perspective view of an extended structure additivemanufacturing device comprising geared wheels and producing an extendedpart having geared guide topography, according to an aspect of thepresent disclosure.

FIG. 6 is a perspective view of an extended structure additivemanufacturing device comprising geared wheels with hemispherical teethand producing a part having guide topography, according to an aspect ofthe present disclosure.

FIG. 7 is a perspective view of an extended structure additivemanufacturing device comprising rollers and producing a part havingguide topography, according to an aspect of the present disclosure.

FIG. 8 is an exploded view an extended structure additive manufacturingdevice comprising rollers, according to an aspect of the presentdisclosure.

FIG. 9 is a side view of an extended structure additive manufacturingdevice comprising treads, according to an aspect of the presentdisclosure.

FIG. 10 is a bottom perspective view of an extended structure additivemanufacturing device comprising treads, according to an aspect of thepresent disclosure.

FIGS. 11A & B are views of an extended structure additive manufacturingdevice comprising worm gears and producing a part having guidetopography, according to an aspect of the present disclosure.

FIG. 12 is a side view of an extended structure additive manufacturingdevice comprising thrusters, according to an aspect of the presentdisclosure.

FIG. 13 is a side view of an extended structure additive manufacturingdevice comprising thrusters and grappling arms, according to an aspectof the present disclosure.

FIG. 14 is a side view of an extended structure additive manufacturingdevice comprising thrusters and grappling arms and depicting anexemplary material source, according to an aspect of the presentdisclosure.

FIG. 15 is a perspective view of an extended structure additivemanufacturing device having arms with fine and gross control elements,according to an aspect of the present disclosure.

FIG. 16 is a perspective view of an extended structure additivemanufacturing device having multiple material bonding components,according to an aspect of the present disclosure.

FIG. 17 is a side view of an extended structure additive manufacturingdevice having additional arms, each arm including an additional bondingcomponent, according to an aspect of the present disclosure.

FIG. 18 is a perspective view of an extended structure additivemanufacturing device having an articulating arm including a scanningdevice, according to an aspect of the present disclosure.

FIG. 19 is a perspective view of extended structure additivemanufacturing device including a build tray, according to an aspect ofthe present disclosure.

FIG. 20 is a side view of an extended structure additive manufacturingdevice having extended vertically oriented rollers, according to anaspect of the present disclosure.

FIG. 21 is a perspective view of an extended structure additivemanufacturing device creating a circular dish, according to an aspect ofthe present disclosure.

FIG. 22 is a perspective view of an extended structure additivemanufacturing device creating a large cylinder, according to an aspectof the present disclosure.

FIG. 23 is a perspective view of an extended structure additivemanufacturing device creating a multi-truss structure, according to anaspect of the present disclosure.

FIG. 24 is a flowchart illustrating an exemplary process for creating apart, namely an extended structure, using an extended structure additivemanufacturing device, according to an aspect of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed apparatus, systems, and methods whichenable additive manufacturing of large continuous structures. Suchstructures may be constructed without providing a build volume largerthan the structure being produced. In various aspects, devices inaccordance with the present disclosure may function in environments suchas outer space environments, microgravity environments, terrestrialenvironments, free fall environments, nautical environments, variableforce environments, other controlled environments, and the like. Devicesin accordance with the present disclosure may create desired parts asobjects, structures, expendable parts, replacement parts, experimentalobjects, make-shift repairs, portions of any of the foregoing, and thelike. Instructions for the production of such parts may bepre-programmed within the device, provided by a local computing device(e.g., a computing device on a space station containing the additivemanufacturing device), transmitted from a remote location (e.g.,received from a remote server, received from a computing device onanother celestial body or spacecraft), or received or generated atanother location apparent to those skilled in the relevant art(s) afterreading the description herein.

Extended structure additive manufacturing devices and the associatedmethods disclosed herein have many applications for building largestructures, parts, and objects. It can be used to build any objectgreater than a typical machine's build volume. Such applicationsinclude, but are not limited to creating: beams for the construction ofbuildings; infrastructure of large skyscrapers; large antenna andcommunication devices; generative designed structures createdspecifically for their intended use; large structures in outer space;conduit and piping for building construction, including pipes with 90°turns; fuselages or portions thereof (e.g., aircraft fuselages); vehiclechassis and frame; portions of ships, submarines and the like; pressurevessels; and other large and small objects.

When creating a structure in outer space, several challenges andopportunities arise. In general, creating a structure in outer space ispreferable to building that structure on earth and transporting it toouter space for final assembly. By creating the structure in outer space(hereinafter “space”), that structure is not subject to the stresses ofgravity, the vibration and additional acceleration forces from launch,and therefore it requires far less mass and overbuilding. The part mayweigh far less and take up far less payload volume as a result.

Large-scale parts cannot be achieved simply by transporting theequivalent of a modern additive fabrication machine into space due tothe “build volume” constraints. Devices in accordance with the presentdisclosure may be used to build large parts, continuous structures andother objects in space. Examples of potential space-based applicationsinclude building: large structures; mega structures; space stations;space-based solar power infrastructure; satellite components; dockingstations; fuel depots; asteroid mining infrastructure; spacecraft(manned or unmanned); planetary body development infrastructure;generative designed structures; created specifically for their intendeduse; larger than deployable stiff beams and trusses; or portions of anyof the foregoing.

Devices in accordance with the present disclosure enable production ofcontinuous parts larger than any given build volume. With the extendedstructure additive manufacturing method, either the device or the partbeing created moves as it builds a three-dimensional part. Duringcreation, the part being built extends beyond the build area. The devicecan move by interfacing with worm gears, wheels, propulsion, or otherknown methods of traversing.

Various devices in accordance with the present disclosure may functionin a pressurized environment (e.g., within a spacecraft), in a spaceenvironment, on a celestial body, while being exposed solar radiation,large thermal extremes and gradients, atomic oxygen and the like.

Referring now to FIGS. 1-3, various views of an extended structureadditive manufacturing device 100 which is producing a part 102,according to various aspects of the present disclosure, are shown.

The term “part” may be used herein to refer to objects created in wholeor in part by extended structure additive manufacturing devicesdisclosed herein. Such objects may be continuous structures which extendaway from the material bonding component as they are created. Examplestructures, such as beams or supports, may be generally linear inprofile. Other structures, such as a pressure vessel, communicationsarray, conduit, or portions of a spacecraft may have more complex orirregular profiles.

Extended structure additive manufacturing device 100 may have a bodyand/or a frame 104, material bonding system 202, and a movementmechanism 106 configured to move the additive manufacturing devicerelative to the part during part creation. Material bonding system 202may include a movable material bonding component 204 connected to amaterial bonding component positioning system 202 such as the traverseshown in FIG. 2. Positioning system 206 moves material bonding component204 within device 100. In various aspects, material bonding system 202includes multiple material bonding components 204 moveable via one ormore positioning systems or via portions of movement mechanism.

In an aspect, positioning system 206 is a traverse system. Traversesystem 206 physically interfaces with and is supported by frame 104. Thetraverse system may include multiple linear actuators oriented in one ormore axes. Each linear actuator includes a stepper motor connected to agear box which rotates a screw-driven linear rail. A carriage isconnected for movement to the rail, enabling precise positioning of thecarriage and attached components such as other linear actuators andmaterial bonding component 204.

In some aspects, positioning system 206 is omitted and movementmechanism 106 positions material bonding component 204.

Frame 104 may be a single piece such as a casting or molding, or frame104 may be formed of multiple pieces. Frame 104 may include multipleportions housing modular and/or interchangeable components (e.g.,control electronics modules, feedstock modules, and the like). In someaspects, frame 104 is a monocoque structure.

Material bonding system 202 may be part of an additive manufacturingdevice that has stationary parts secured to or part of the frame 104 aswell as one or more movable parts used to print materials such asmaterial bonding component 204, so that material bonding component 204may move relative to frame 104. Material bonding component 204 may be anextruder which melts received feedstock, such as a polymer filament, andplaces, via positioning system 206 and movement mechanism 106, meltedfilament in order to create the desired part. Material bonding component204 may comprise a selective laser sintering (SLS) mechanism or directmetal laser sintering mechanism (for which the movable portion may bepart of a scanner system that is part of device 100). In some aspects,material bonding component 204 may be a welding device such as anelectric arc welder, an energy beam welder, an oxy-fuel or gas welder, aresistance welder, or a solid state welder. In other aspects, thematerial bonding component 204 may be a stereolithography device, aninkjet head, a cladding head, a concrete or other solidifying materialdeposition device, or any other device apparent to those skilled in therelevant art(s) after reading the description herein. Where multiplematerial bonding components 204 are utilized, such multiple materialbonding components 204 may bond or otherwise deposit different materialsor have different characteristics (e.g., different resolutions).

A conventional printer has a print volume that is defined by the rangeof movement of the print-head. Device 100 enables continuous partcreation outside of the print volume defined by the printer, therebyproviding an expanded area available for creating part 102 that is notfound in conventional additive manufacturing machines.

During part 102 creation, device 100 moves relative to part 102 and viceversa via movement mechanism 106. Movement mechanism 106 may be any oneor more of various propulsion mechanisms. One such propulsion mechanismis a movable engagement mechanism, such as one or more fixed or movablearms 110. Arms 110 may be rigid or articulated with one or more joints108 such as hinges and/or ball-joints. Arm 110 may include grippingclaws 112 or other portions which may interface and/or stabilize part102. In other aspects, movement mechanism 106 may include rollers,movable tracks, worms, wheels (including cog wheels such as gears,pinions, and wheels with ball rollers), or directable thrusters (such asa small jet or rocket thruster). The drive for such movement mechanisms106 may be mechanical and/or electrical (such as via motor and optionalgearbox and/or cables and pulleys; rack and pinion) and/or hydraulic(such as via hydraulic fluids and pistons connected to movableportions). Movement mechanism 106 may be e.g., mechanical and/orchemical (as in a rocket).

Extended structure additive manufacturing device 100 may additivelyconstruct part 102 beneath it. When device 100 reaches the extent of theconventional “build volume” defined by material bonding system 202,however, device 100 actually “climbs” part 100 being constructed and/ormoves the structure outside of the ESAMM's traditional “build volume.”Therefore the ESAMM is able to create an additional, continuous,sequential portion of part 102, thereby generating part 102substantially larger than device where desired.

As the printed portion of part 102 grows larger and/or longer, device100 may climb or otherwise maneuver along part 102 at a necessary paceso that material bonding system 202 remains at the correct distance topart 102. In some aspects, material bonding component 204 is coupled ordecoupled from the movement mechanism 106. Decoupling would enabledevice 100 to have variable levels of adjustment, allowing more accuracyto the bonding surface (e.g., the print surface) than movement mechanism106 would otherwise allow. For example, where movement mechanism 106allows for large steps (1 mm, 1 cm, 1 m, etc. depending on application)in a z-axis, material bonding system 202 may include traverse 206 whichmoves material bonding component 204 in the given z-axis in finer steps(10, 20, 100 microns, etc. depending on application). In this fashion,device 100 may create several layers of part 102 without repositioningpart 102 via movement mechanism.

As a result, very complex structures could be created this way,irrespective of the limitations imposed by length, many moreconventional fabrication technologies, or gravitational pull.

In an aspect, movement mechanism 106 may include arms 110 having roboticmanipulators such as claws 112. Arms 110 may have up to 6 degrees offreedom with the help of electromechanical devices such as servo motorsalong each arm 110. In other aspects arms 110 may have more of fewerdegrees of freedom. Arms 110 are used to position actuating grippingmechanisms (claw 112) to grab ahold of the created part 102 androbotically maneuver relative to part 102. The manipulators and arms 110can range in size, quantity, and position to achieve the same type ofclimbing movement along a manufactured item as well as structures thatalready exist that need to be manufactured on.

In other aspects, arm 110 includes a gripping foot. The gripping footmay have an adhesive applied thereon, have a high friction contactsurface, be deformable, include electrostatic adhesion elements, vacuumor other suction attachment elements, or the like in order to attach topart 102 in the desired manner.

In other aspects, arms 110 include devices which facilitate climbingpart 102 in a similar fashion to recreational, Earth-based climbing.Devices include modules which tap into part 102 using an anchor for ahold while maneuvering, creating anchors along part 102 to use in placeof post manufacturing anchor integration/use. Picks and other surfacedrilling devices can be used also to “bite” in a surface to allowmaneuvering.

In various aspects, device 100 includes or is connected to one or morefeedstock sources. Feedstock is any material or combination of materialssuitable for the production of a part. Feedstock may be plastic, metal,organic material, inorganic materials or combinations of such materials.As will be apparent to those skilled in the relevant art(s) afterreading the description herein, materials such as acrylonitrilebutadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), highdensity polyethylene (HDPE), polyphenylsulfone (PPSU), soldering wire,polymer matrix composites, polyether ether keytone (PEEK), bismuth,aluminum, titanium, tin, and the like may be used to produce desiredparts via additive manufacturing. In some aspects, feedstock is in theappropriate state, shape, size, and/or other physical characteristicsuitable for utilization by the material bonding component. Feedstockmay be produced from asteroid regolith, regolith of other celestialbodies, from space debris, from trash, from obsolete parts, and thelike. In some aspects, feedstock is a polymer filament containing metalpowder. In another aspect, feedstock is a polymer containing carbonnanotubes, fibers, or the like. In yet another aspect, feedstock is aresin, a resin containing a filler, binder, and/or powder, or the like.Feedstock may be a liquid or a combination of materials having differentphysical states (e.g., a solid and a liquid).

In some aspects, device 100 includes control electronics mounted withinor on to frame 104. Control electronics may operate portions of device100 and/or receive operational commands from other sources viamechanisms apparent to those skilled in the relevant art(s) afterreading the description herein.

Although part 102 shown in FIGS. 1-3 is a linear beam, device 100 may beutilized to produce parts 102 having non-linear profiles. For example,device 100 may produce a dish-shaped part 102 of any desired size (e.g.,10 meters, 100 meters, 1 or more kilometers). Device 100 may producecomplex structures such as a lattice, a pressure vessel, a spacecraftmodule, and the like.

In some aspects, the print area may be angled relative to previouslycreated layers of part 102. This is one manner of creating a curvedportion of part 102. Device 100 may be oriented in this fashion andspiral inward, creating a dish or other circular structure. As will beapparent to those skilled in the relevant art(s) after reading thedescription herein, device may be oriented in other manners or createportions of part 102 in other ways in order to create the desired linearor non-linear structure of part 102.

Referring now to FIGS. 4A, 4B & 5, various views of extended structureadditive manufacturing device 100 comprising geared wheel arms 404having articulable wheels 408 held within axle 406, according to variousaspects of the present disclosure, are shown. Wheel 408. In otheraspects, device 100 includes additional portions of moving mechanism 106which cause device to move relative to part 102. Device 100 may producepart 102 having guide topography 402, such as the columns of teeth shownin FIGS. 4A-B. Guide topography 402 is any structure created by device100 which interfaces with movement mechanism 106 in order to assist inmaintaining positioning between part 102 and device 100. Guidetopography 402 may be integrated into part 102 or added to the desireddesign of part 102 before part production. Guide topography 402 may becontinuous, as shown in FIGS. 4A-5, or created periodically. For examplea recessed annulus may be integrated into the surface structure of part102 at defined intervals, providing a place for movement mechanism togrip part 102 as it is produced. Guide topography 402 may be one or morecolumns of spur teeth (as shown in FIG. 4), worm teeth (as shown in FIG.11), helical teeth, or the like. Guide topography 402 may be a series ofindentations (as shown in FIG. 7) or a series of protrusions. Guidetopography 402 may include a roughened surface or other features whichincrease frictional forces between movement mechanism and part 102. Aswill be apparent to those skilled in the relevant art(s) after readingthe description herein, guide topography 402 may be any regular orirregular surface treatment which facilitates guiding and positioningpart 102. In various aspects, no guide topography 402 is created.

Wheel 408 includes a toothed surface enabling interaction with a flatgear surface topography 402 or a rack surface topography 42. In otheraspects, wheel 408 has a spur gear or helical gear surface, enablinginteraction with surface topography 408 configured to create a spur gearor helical gear.

Gear wheel arms 404 may or may not be spaced evenly around frame 104. Insome aspects, gear wheel arms 404 can have up to 6 degrees of freedomwith the help of electromechanical devices such as servo motors alongeach arm 404. At the base of each arm 404 is a motor and spur gear wheel408 that locks into the part at surface topography 402. While thevertical translation is controlled primarily by arms 404, an adjustmentmechanism ensures that the material bonding component 204 stays withinan ideal range. Control electronics may rest on top of device, but canbe moved anywhere and/or housed within an enclosed structure, or couldalso be unenclosed.

Movement mechanism 106 configured as a multi-armed gear mechanism, whichcould have two, three, four, five six, or more arms, may provide threemain benefits. First, by using gears and designing structures thatincorporate teeth or without teeth and using another solution, a desiredclimbing rate is ensured (I to I, 2 to I, 3 to I, etc.). Second, thearms can move in and out easily to allow for a variety of diameters,even within the same structure. Finally, gearclimbing rates can beadjusted to create curved structures, allowing movement beyond 1-axiscreations.

Referring briefly now to FIG. 6, extended structure additivemanufacturing device 100 comprising geared wheels 408 with hemisphericalteeth and producing part 102 having guide topography 402, according toan aspect of the present disclosure, is shown. Part 102 may be producedwith outer guide portions housing guide topography 402. Such outer guideportions may be removable from the desired structure 604 via crossmembers 602. After creation of part 102, the outer guides and crossmembers 602 may be removed, leaving the desired portion 604 forutilization.

Referring now to FIGS. 7-8, various views of extended structure additivemanufacturing device 100 comprising rollers and producing a part havingguide topography

In some aspects, moving mechanism 106 may include two of more rollerarms 702. Each roller arm 702 includes a roller 704. In other aspects,roller arms 702 include rotating balls or other objects which may rollalong a track containing indentations or along the smooth surface ofpart 102. Part 102 may include surface topography 402 which creates aseries of indentations along a long axis of part 102. Roller arms 702may be controlled by actuator 706, providing a variable force andallowing device 100 to accommodate parts 102 of varying cross sections.The force of roller arms 702 is variable to adjust for any sizedcontours without slipping. Rollers 704 can range in size, quantity (one,two, three or more), and position to achieve the same type of climbingmovement along a manufactured part 102 and the materials used for therolling mechanisms can range for any operational purposes (e.g.adhesive, high friction, soft).

Referring now to FIGS. 9-10, various views of extended structureadditive manufacturing device 100 comprising treads arms 902, are shown.

Moving mechanism 106 may include tread arms 902. Each tread arm 902 mayinclude two or more treads 904 which articulate, allowing treads 904 tocontact sides of part 102. Treads 904 can swing in and out depending onthe angle of contact with part 102. Like gear-based devices 102, devicesincluding tread arms 902 have the ability to change diameters during abuild, as well as from one part 102 to the next. Unlike the gearedsystem, the structure does not have to be designed specifically to fittreads 904. As long as the treads can make consistent contact with theouter surface of part 102, positioning may be maintained.

Referring now to FIGS. 11A-B, views of extended structure additivemanufacturing device 100 comprising worm gears 1102 and producing part102 having guide topography 402, according to an aspect of the presentdisclosure, are shown.

In an aspect, device 100 may include two, three, four or more mobile orimmobile worm gear arms 1102 each including a motorized worm gear. Thisgear will thread into the teeth of guide topography of part 102 duringpart creation.

Referring now to FIG. 12, a side view of extended structure additivemanufacturing device 100 comprising thrusters 1202, according to anaspect of the present disclosure, is shown.

In some aspects thrusters 1202 such as RCS thrusters or similar devicesor thruster pods may be integrated into device 100 in lieu of or inaddition to other portions of movement mechanism 106. Such aconfiguration allows device 100 to move along the part 102 being createdwithout any direct contact.

Referring now to FIG. 13, a side view of extended structure additivemanufacturing device 100 comprising thrusters 1202 and grappling arms110, according to an aspect of the present disclosure, is shown.

In various aspects, movement mechanism 106 includes fine movementcontrol devices and gross movement control devices. Thruster 1202 may bean example of a gross movement control device, capable of moving device100 large distances and not capable of precisely and quickly positioningdevice 100 over smaller distances. Thruster 1202 may also move device100 from one area to another. For example, device 100 may produce a 100meter long truss and transit, via thruster 1202 or similar propulsivedevice to a midpoint of the truss and begin creating a second trussconnected and orthogonal to the first truss, thereby forming a morecomplex part 102. Fine movement devices include arm 110, roller arm 702,tread arm 902, gear arm 404 and the like. Fine movement devices grabonto or otherwise contact part 102 and stabilize device 100 relativepart 102. Via such fine movement control devices, device 100 may travel“up” part 102 as it is creates. Some fine movement control devices maybe used to move or traverse device 100 along part 102.

Referring briefly now to FIG. 14, a side view of extended structureadditive manufacturing device 100 comprising thrusters 1202, grapplingarms 110 and a representative material or feedstock source 1402,according to an aspect of the present disclosure, is shown. Materialsource 1402 houses and/or produces feedstock. In some aspects, materialsource 1402 is integrated into device 100. In other aspects, materialsource 1402 is detachable, replaceable or refillable. In yet otheraspects, material source 1402 is another device, vehicle, or body.

Referring now to FIG. 15, a perspective view of extended structureadditive manufacturing device 100 having arms 1502 with fine controlelements and gross control elements, according to an aspect of thepresent disclosure, is shown.

In an aspect, movement mechanism 106 includes one or more combinationarms 1502. Each combination arm 1502 has fine motors 1504 or othermechanisms or assemblies which allows small-scale movement (1 cm stepsize or less) of device 100. Each combination arm also include grossmotors (positioned within frame 104 in FIG. 15) or other mechanisms orassemblies which allow large-scale movement (e.g., 10 cm step size ormore). Fine motor 1504 is a fine movement control devices. Gross motoris a gross movement control devices. Gross motor 1506 and/or other grossmovement control devices may be high torque devices, capable of joiningobjects together or imparting significant force on an object or objects.Gross motor 1506 may also be used to push device 100 off a surface,providing propulsion.

In some aspects, device 100 may include additional additivemanufacturing devices or portions thereof mounted on an arm 1502. Forexample, an arm-mounted extruder 1508 may be positioned on an endportion of arm 1502, thereby allowing structures or portions ofstructures to be created with extruder 1508. In some aspects, an entireadditive manufacturing device may be mounted on the end of arm 1502 or,more generally, a portion of movement mechanism 106. In other aspects,only deposition or bonding portions of the additive manufacturing deviceare mounted on the end of arm 1502. In such cases, the deposition orbonding portion is operatively connected to a feedstock source and otherportions necessary for the creation of structures. Arms 1502 may containchannels, pathways or other structures which connect extruder 1508, aprint head or the like to a feedstock source housed within or connectedto device 100. As will be apparent to those skilled in the relevantart(s) after reading the description herein, other constructing,repairing, inspection, and/or observation devices may be mounted on arms1502.

Referring now to FIG. 16, a perspective view of extended structureadditive manufacturing device 100 having multiple material bondingcomponents 204, according to an aspect of the present disclosure, isshown. Device 100 may include multiple material bonding components 204.Such bonding components 204 may connected to frame 104, connected to thesame or multiple traverses 206, connected to portions of movementmechanism 106 connected for movement to manipulator arms, or have otherconnections apparent to those skilled in the relevant art(s) afterreading the description herein. Material bonding components 204 may eachbond different types of materials and/or bond material via differentmechanisms (e.g., fused deposition modeling, welding, and the like).Device may include multiple movement devices including thrusters 1202,arms 1502 (not shown in FIG. 16, and the like. Bonding components 204may create structures and portions thereof using the same materials ordifferent types of materials.

Referring now to FIG. 17, a perspective view of extended structureadditive manufacturing device 100 having additional arms 1702, each armincluding an additional bonding component 204, according to an aspect ofthe present disclosure, is shown. Device 100 may include multiplebonding components 204 configured for different materials, constructionresolutions, and the like. For example, device 100 may include onebonding component 204 a which produces high-resolution parts viaextrusion of a thermoplastic and a second bonding component 204 b whichproduces lower resolution parts via extrusion. In some aspects, arm 1702comprise all or a portion of positioning system 206.

Referring now to FIG. 18, a perspective view of extended structureadditive manufacturing device 100 having an articulating arm 1802including an accessory 1804, namely a scanning device, according to anaspect of the present disclosure, is shown.

Device 100 may include one or more arms 1802 having accessories 1804.For example, accessory 1804 may be a scanner (as shown in FIG. 18), acamera, or other detection device. Accessory 1804 may also be amanipulator arm, claw or other device as shown in, for example, FIG. 15.As will be apparent to those skilled in the relevant art(s) afterreading the description herein, accessory 1804 may be any mechanismwhich facilitates creating part 102, ensuring the quality of part 102,assists in joining part 102 to other objects, and the like.

Referring now to FIG. 19, a perspective view of extended structureadditive manufacturing device 100 including a build tray 1904, accordingto an aspect of the present disclosure, is shown. Accessory 1804 may bebuild tray 1904, providing a surface for creating parts 102 and portionsthereof.

Referring now to FIG. 20, a side view of extended structure additivemanufacturing device 100 having extended vertically oriented rollers2002, according to an aspect of the present disclosure, is shown. Roller2002 facilitate movement of device 100 across structures including part102 created by bonding component 204. Thrusters 1202 may be utilized totransit device 100 from one portion of part 102 to another or from onearea to another.

Referring now to FIGS. 21-23, a perspective view of extended structureadditive manufacturing device 100 creating non-linear structures 102,according to various aspects of the present disclosure, are shown.

Device 100 may create curved structures 102, such as a dish as shown inFIG. 21 or the large cylinder shown in FIG. 22. Various portions ofmovement mechanism 106 may be utilized to reorient device 100, enablingthe creation of non-linear structures. For example, thrusters 1202 androllers 2002 may be used to reorient and guide device 100 as structureis created. Movement mechanism 206 which positions bonding component 204may also place bonding component 204 such that a complex structure maybe created.

Device 100 may create a first portion of a structure 102, such as afirst truss 2302 and then be reoriented and create additional portionsof structure 102, such as a second truss 2304 connected to first truss2302 and extending away from first truss 2302.

Referring now to FIG. 24, a flowchart illustrating an exemplary process2400 for creating part 102 using extended structure additivemanufacturing device 100, according to an aspect of the presentdisclosure, is shown.

Process 2400 begins as step 2402 with control immediately passing tostep 2404.

At step 2404, device 100 receives all or a portion of print instructionsfor part 102. In some aspects, control electronics adds guide topography402 or other structures to part instructions in order to facilitate part102 creation by device 100.

In various aspects, device 100 contains print instructions and step 2404may be omitted.

At step 2406, a first portion of part 102 is received by device 100. Thefirst portion may be produced by another additive manufacturing device,or supplied from another source (e.g., produced by other methods). Thefirst portion serves as a based to create part 102. Other portion may bereceived and integrated into part 102 during the part creation process.For example, reinforcing rods may be periodically added.

In other aspects, the first portion has been previously created bydevice 100. For example, a first truss is provided. Process 2400 isutilized to create additional structure connected to the provided firsttruss.

At step 2408, the first portion of part 102 is positioned within device100 in order to facilitate creation of part 102.

In various aspects, device 100 creates part 102 without utilizing afirst portion provided by another source. Steps 2406 and 2408 may beomitted.

At step 2410, device 100 creates a portion of part 102 such as one ormore layers. Where material bonding system 202 includes z-axis movement,multiple layers may be produced.

At step 2412, after device 100 can no longer produce layers of part 102in the current position relative to part 102, it is determined if part102 is complete. If part 102 is complete, step 2416 executes, endingprocess 2400. If part 102 is incomplete, moving mechanism 106repositions device 100 and/or part 102 to enable creation of additionalportions of part 102 by device 100.

In this manner, device 100 may create portions of part 102 as device 100moves relative to the object or device 100 may create a portion, ceasecreation, reposition itself relative to part 102 and recommence creatingportions of part 102. Device 100 may therefore form very long objectssuch as beams, pipes, and the like of essentially unlimited length.

While various aspects of the present disclosure have been describedherein, it should be understood that they have been presented by way ofexample and not limitation. It will be apparent to persons skilled inthe relevant art(s) that various changes in form and detail can be madetherein without departing from the spirit and scope of the presentdisclosure. Thus, the present disclosure should not be limited by any ofthe above described exemplary aspects, but should be defined only inaccordance with the following claims and their equivalents.

In addition, it should be understood that the figures in theattachments, which highlight the structure, methodology, functionalityand advantages of the present disclosure, are presented for examplepurposes only. The present disclosure is sufficiently flexible andconfigurable, such that it may be implemented in ways other than thatshown in the accompanying figures (e.g., utilizing additivemanufacturing devices not mentioned herein, implementation withincomputing devices other than those disclosed herein, and operating inenvironments other than those disclosed herein). As will be appreciatedby those skilled in the relevant art(s) after reading the descriptionherein, certain features from different aspects of the systems, methodsand computer program products of the present disclosure may be combinedto form yet new aspects of the present disclosure.

Further, the purpose of the foregoing Abstract is to enable the U.S.Patent and Trademark Office and the public generally and especially thescientists, engineers and practitioners in the relevant art(s) who arenot familiar with patent or legal terms or phraseology, to determinequickly from a cursory inspection the nature and essence of thistechnical disclosure. The Abstract is not intended to be limiting as tothe scope of the present disclosure in any way.

What is claimed is:
 1. An extended structure additive manufacturingdevice for producing large continuous objects, the extended structureadditive manufacturing device comprising: a frame having at least oneside and an opening from which a part extends from during creation; amovable material bonding component connected to the frame, the materialbonding component configured to receive portions of a material, thematerial bonding component configured to create the part from thereceived material via positioning and bonding each of the portions ofthe received material at a part creation area; and a movement mechanism,comprising at least one arm with a first end attached to the at leastone side of the frame and an attachment to the arm attached at a secondend of the arm to engage the part, configured to move the extendedstructure additive manufacturing device relative to the part.
 2. Theextended structure additive manufacturing device of claim 1, wherein themovement mechanism is configured to move the extended structure additivemanufacturing device relative to the part in a movement mechanismmovement axis extending away from the part creation area; and whereinthe movement mechanism is connected for movement to the frame outsidethe part creation area and outside the opening from which the partextends from during part creation.
 3. The extended structure additivemanufacturing device of claim 2, the attachment to the arm at the secondend comprising at least one articulating griping arm.
 4. The extendedstructure additive manufacturing device of claim 2, the attachment tothe arm at the second end comprising at least one powered gear wheelarm, the at least one gear wheel arm comprising an articulating arm anda powered toothed wheel positioned at an arm end portion and configuredto contact the part.
 5. The extended structure additive manufacturingdevice of claim 2, the movement mechanism comprising at least onemultiple roller arm, the at least one roller arm connected for movementto the frame at a first roller arm end portion and connected formovement to a roller at a second roller arm end portion, the rollerconfigured to contact the part, an actuator connected at a firstactuator end portion to the frame and connected at a second actuator endportion to the roller arm, the actuator controlling the position of theroller arm.
 6. The extended structure additive manufacturing device ofclaim 2, the movement mechanism comprising at least one tread arm, theat lea tread arm connected for movement to the frame at a first treadarm end portion and connected for movement to a tread assembly at asecond tread arm end portion, the tread assembly comprising a foldingframe having two powered treads, the folding frame configured to contacteach of the two powered treads with the part via folding.
 7. Theextended structure additive manufacturing device of claim 2, themovement mechanism comprising at least one powered worm gear arm, the atleast one worm gear arm comprising a vertically oriented powered wormgear configured to contact the part.
 8. The extended structure additivemanufacturing device of claim 2, the movement mechanism comprisingmultiple thrusters positioned on the frame, the thrusters controlled bya position control module to provide for movement of the extendedstructure additive manufacturing device along the part being created. 9.The extended structure additive manufacturing device of claim 8, themovement mechanism further comprising multiple articulating gripingarms.
 10. The extended structure additive manufacturing device of claim1, wherein the material bonding component is a filament extruder. 11.The extended structure additive manufacturing device of claim 1, furthercomprising: a feedstock source comprising the material.
 12. The extendedstructure additive manufacturing device of claim 1, wherein the part iscreated from metal material.
 13. The extended structure additivemanufacturing device of claim 1, wherein the part is created frommultiple materials.
 14. The extended structure additive manufacturingdevice of claim 13, further comprising a second movable material bondingcomponent connected for movement to the frame, the second materialbonding component configured to receive portions of a second material,the second material bonding component configured to create portions ofthe part from the received second material via positioning and bondingeach of the portions of the received second material at the partcreation area.
 15. The extended structure additive manufacturing deviceof claim 1, further comprising a material bonding component positioningsystem connected to the frame and connected for movement to the materialbonding component, the material bonding component positioning systemconfigured to move the material bonding component in three axes.
 16. Theextended structure additive manufacturing device of claim 15, whereinthe material bonding component positioning system is configured to movethe material bonding component in a step-wise fashion in a verticalpositioning axis, the vertical positioning axis parallel to a movementmechanism movement axis, the movement mechanism configured to move in astep-wise fashion in the movement mechanism movement axis; and wherein amaterial bonding component positioning system vertical positioning axisminimum step size is substantially smaller than a movement mechanismmovement axis minimum step size.
 17. The extended structure additivemanufacturing device of claim 16, wherein the material bonding componentpositioning system vertical positioning axis minimum step size isapproximately equal to a part layer size.
 18. The extended structureadditive manufacturing device of claim 1, further comprising controlelectronics to create guide topography in a created part, the guidetopography contacts the movement mechanism during part creation andstabilize the relative position of the part and the extended structureadditive manufacturing device.
 19. The extended structure additivemanufacturing device of claim 18, wherein the control electronicsfurther creates the guide topography on the created part to include atleast one of: a column of teeth; a worm gear; a plurality ofindentations; roughened surface; and an adhesive surface.
 20. Anextended structure additive manufacturing device for producing largecontinuous objects in outer space, the extended structure additivemanufacturing device comprising: a frame comprising at least one sideand an opening from which a part extends from during creation; a movablematerial bonding component connected for movement to the frame, thematerial bonding component configured to receive portions of a material,the material bonding component configured to create a continuous,space-based part from the received material via positioning and bondingeach of the portions of the received material; a movement mechanismconfigured to move the extended structure additive manufacturing devicerelative to the part, the movement mechanism comprising at least one armwith a first end attached to the at least one side of the frame and anattachment to the arm attached at a second end of the arm to engage thepart; and control electronics to create a guide topography on amanufactured part configured to contact the movement mechanism duringpart creation and stabilize the relative position of the part and theextended structure additive manufacturing device.
 21. The extendedstructure additive manufacturing device of claim 20, wherein guidetopography includes at least one of: a column of teeth; a worm gear; aplurality of indentations; roughened surface; and an adhesive surface.22. The extended structure additive manufacturing device of claim 20,wherein part creation instructions are provided to the controlelectronics to provide for guide topography.
 23. The extended structureadditive manufacturing device of claim 22, wherein the controlelectronics add guide topography after receiving an initial part designfile at the extended structure additive manufacturing device.
 24. Theextended structure additive manufacturing device of claim 1, wherein acombination of the frame, the movable material bonding component and themovement mechanism are arranged to create the part while at least one offree floating and free falling in at least one of an outer spaceenvironment, a microgravity environment, a free fall environment, anautical environment, and a variable force environment.
 25. The extendedstructure additive manufacturing device of claim 20, wherein acombination of the frame, the movable material bonding component and themovement mechanism are arranged to produce the large continuous objectsin outer space while free floating in at least one of an outer spaceenvironment and a microgravity environment.
 26. The extended structureadditive manufacturing device of claim 1, wherein the second end of thearm to engage the part comprises at least one of electrostatic adhesionelements, a vacuum element and a section element to provide for the armto engage and disengage from the large continuous object be produced tomove the extended structure additive manufacturing device relative tothe part.
 27. The extended structure additive manufacturing device ofclaim 1, wherein the second end of the arm to engage the part comprisesat least one of electrostatic adhesion elements, a vacuum element and asection element to provide for the arm to engage and disengage from thelarge continuous object be produced to move the extended structureadditive manufacturing device relative to the part.